from waste to alternative fuel

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FROM WASTE TO ALTERNATIVE FUEL

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YOUR RELIABLE COMPLETE SOLUTION FOR ULTIMATE PLANT PERFORMANCE

TAILOR-MADE SOLUTIONS FROM A TEC

A COMPREHENSIVE SOLUTION TO COVER ALL CRUCIAL STEPS

PLANT INVESTIGATION

• Evaluating the existing system

• Investigating available space for installing equipment

• Analyzing possible conversion scenarios to increase the substitution rate

MARKET SURVEY

PYROPROCESSING

• Pyroprocessing calculation with the available AF

• Evaluating the impact on the entire process

• Assessing the remaining capacity required from existing equipment and modification works

ENGINEERING

• Innovative products

• Basic plant layout

• Detailed plant design and component design

SUPPLYING EQUIPMENT

• Innovative products to optimize the entire process

• MASTER System to significantly increase the TSR

PLANT CONSTRUCTION

• Modifications to the existing system

• Full service during erection and day-to-day operations

PLANT INVESTIGATION

FEASIBILITY STUDY

PYRO- PROCESS

SUPPLYING EQUIPMENT

PLANT CONSTRUCTIONENGINEERING

IMPROVED ENVIRONMENTAL BALANCE

The shift to alternative fuel firing is of high pri-ority at A TEC. By using modern and innova-tive technologies, combined with our process know-how, we are able to reduce costs and offer reliable solutions for the reduction of en-vironmental impacts in the cement industry.

ALTERNATIVE FUEL SYSTEM

Based on our expert knowledge in pyropro-cessing and alternative fuel preparation, we have comprehensively optimized waste pre-paration and pyroprocessing. With a comple-te and unique alternative fuel system, A TEC covers all crucial steps from engineering to supplying equipment and plant construction.

As a complete system supplier with long- term experience in waste treatment and hand-ling, we are able to guarantee significant commercial and environmental benefits:

• Sustainable cost reduction• Fast amortization• Up to 100% substitution rate• Compliance with environmental regulations• Process guarantees• Complete solution from a single source

MARKET SURVEY

• Sourcing available alternative fuels

• Evaluating quantities

• Researching collecting systems and conditions

FEASIBILITY STUDY

• Detailed process calculations and simulations

• Conceptual design of the plant

• Estimating investment and operating costs

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DETAILED ANALYSIS

Before implementing a tailor-made alternative fuel system it is essential to carry out a detailed

market survey. We take a look at sourcing available alternative fuels, and we evaluate the quantities of existing alternative fuels and research collecting systems and conditions.

RESEARCH ON SITE

After getting an idea of the preconditions, a team of engineers evaluate the existing system on site. The aim of the plant investigation is to identify available space for installing equip-ment, as well as analyzing possible conversion scenarios to increase the substitution rate.

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MARKET SURVEY PLANT INVESTIGATION01

01 DETAILOVERVIEW

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FLEXIFLAME – ROTARY KILN BURNER ECOPRO®

With three types of airflows and a unique de-sign, the burner uses simple procedures to optimize complex fuel firing and attain better control over NOx emissions. The burner delivers a thermal output of up to 175 MW and can use just one or multiple fuels, with a variable mix.

• Increased control over NOx emissions

• Enhanced control over ring formation

• More control over the sulfur cycle

• Better clinker product quality

• Longer refractory service life

• More flexibility with flame control

• Better process stability

ROCKET MILL

The Rocket Mill is the next step in the prepa-ration of alternative fuels. Effective grinding is possible in one step. With this grinding technology a drying effect of approx. 10% is achieved. Additional drying with process gas for very wet alternative fuels is possible (dry-ing rate more than 10%). The ultra-fines are dusted and also dosed to the kiln system.

• Size reduction from 250mm to 5mm in one step

• Easy to operate and maintain

• No knives to keep sharp

• Separation of metal materials

• Different output fuel particle sizes possible

• Drying effect of AF from 10% upward

• High resistance to foreign objects

SUPPLYING EQUIPMENT06

DRYING

A TEC has patented a special procedure for processing alternative fuels; it allows AF to be dried using waste gas during the crushing process in rotary crushers. This new procedure optimizes the quality and capabilities of AF, thus enabling maximum substitution rates. Additionally A TEC offers conventional drying processes combined with simultaneous separation of dense media.

VAST EXPERIENCE

Based on the collected data and the customer’s demands, our technicians create tailor-made basic engineering techniques, including a detailed plant design and a component design. Computer-aided simulations of process para-meters after modifications provide a precise representation of possible achievements.

ENGINEERING05

The core of our equipment is the so-called MASTER System – Maximum Alternative Sub-stitution To Environmental Recovery. By combining the Rocket Mill and FLEXIFLAME Rotary Kiln Burner Ecopro®, a substitution rate of 100% of solid alternative fuel is achievable.


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COMPLETE EVALUATION

To develop a complete system, a feasibility

study with detailed process calculations and simulations will be carried out by our experts. A TEC estimates investments, operating costs and creates a conceptual design of the plant.

OPTIMIZATION OF THE CORE

Pyroprocessing is the core of a complete alterna-tive fuel system. A TEC generates pyroprocessing calculations with the available alternative fuels, evaluates the impact on the entire process and assesses the remaining capacity required from existing equipment and modification works.

FEASIBILITY STUDY 03

PYROPROCESSING 04

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COMBUSTION CHAMBER

Our combustion chamber significantly improves the combustion process by using tertiary air with 21% oxygen. A significantly higher temperature can be achieved, compared to conventional calci-nes, due to the closed volume combustion. Ano-ther advantage is the increase in retention time, which allows the combustion of bigger particles.

SWING CHUTE

The swing chute is used as safety equipment for feeding alternative fuels into the combustion system. In the event of an operating problem, the gravity-driven chute swivels out and com-pletely closes the furnace system off from the alternative fuels feed. No drive is needed.

BESIDES THE MASTER SYSTEM, ADDITIONAL HIGH-PERFORMANCE EQUIPMENT FROM A TEC

PROVIDES THE BEST ENABLING TECHNOLOGY FOR THE WHOLE ALTERNATIVE FUEL SYSTEM.

POST COMBUSTION CHAMBER

The mixing of combustion exhaust, tertiary air streams and unburnt fuels can be hugely improved using our Post-Combustion Chamber. This results in better combustion and lower CO emissions.

REDUCHLOR® BYPASS

The REDUCHLOR® Bypass prevents chlorine from circulating during the combustion process. This can be ensured using a take-off chamber above the kiln inlet (specifically designed for each installa-tion) and a maintenance-free quenching chamber where the chlorine condensates and adheres to the fine dust particles. After this condensation process, the Cl-enriched material is collected in a filter.

COUNTER ROTATING SCREEN DRUM

The Counter-Rotating Screen Drum is an excellent solution for domestic, industrial or plastic waste. Each screening section is equipped with housing and a connection flange on top to eliminate odor and fine dust, especially for indoor arrangements.

DeNOX SYSTEM

The DeNox System is your way to minimize

NOx emissions below the limit of 200 mg/Nm³.

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LOCAL EXPERTISE

Finally, the modifications are implemented to the existing system on site. We support our customers during the reconstruction or erection, and afterwards during day-to-day operations.

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A TEC Production & Services GmbH

Finkensteiner Straße 99585 Gödersdorf, Austria

Phone: +43 4257 3600Fax: +43 4257 3600 101

[email protected]

from waste to alternative fuel

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